INSTALLATION MANUAL FOR RHPS CONTROL SYSTEMS ON HYDRAULIC PRESS BRAKES Remote Operator Station Safety Camera System IMPORTANT: PLEASE REVIEW THIS ENTIRE PUBLICATION BEFORE INSTALLING, OPERATING, OR MAINTAINING THE SOLID-STATE HYDRAULIC CONTROL SYSTEM. 4620 Hydraulic Road • Rockford, Illinois 61109 • Toll-Free 1-800-922-7533 • Phone 815-874-7891 Fax 815-874-6144 • Web Site www.rockfordsystems.com • E-Mail [email protected] Manual No. KSL-278 sectionTABLE OF 1—in CONTENTS general RHPS Hydraulic Solid-State Control SECTION 1—iN GENERAL ..................................................................................................................................... 3-5 SE CTION 2—intRODUCTION ............................................................................................................................. 6-13 SE CTION 3—inSTALLATION OF COMPONENTS ........................................................................................... 13-32 Introduction .....................................................................................................................................................13-15 Control Box .....................................................................................................................................................15-22 Timing Devices ...............................................................................................................................................23-24 Palm Button Assembly ....................................................................................................................................25-27 Foot Switch .....................................................................................................................................................28-29 Supervisory Control Station ................................................................................................................................. 29 Multiple Operator Junction Box ............................................................................................................................ 29 Other Components ..........................................................................................................................................30-31 Other Installation Considerations ....................................................................................................................31-32 SECTION 4—PROGRAMMING ........................................................................................................................... 33-45 Power-Up Procedure ......................................................................................................................................33-34 User Inputs ......................................................................................................................................................35-36 Counters .........................................................................................................................................................37-38 Anti-Tie-Down ...................................................................................................................................................... 39 Security Code ...................................................................................................................................................... 40 Restore Factory Defaulit Settings ........................................................................................................................ 41 Muting .................................................................................................................................................................. 42 Auto Return .......................................................................................................................................................... 43 Decompress Timer ............................................................................................................................................... 44 Block Valve Delay ................................................................................................................................................ 45 Spanish ............................................................................................................................................................... 46 Configuration Menu .........................................................................................................................................47-48 Configuration Security Code ................................................................................................................................ 49 Bottom Dwell ...................................................................................................................................................42-45 SECTION 5—TROUBLESHOOTING AND FAULT MESSAGES ........................................................................51-52 SECTION 6—opeRATING CONSIDERATIONS .................................................................................................53-54 SECTION 7—mAINTENANCE AND INSPECTION .................................................................................................. 55 SECTION 8—methodS OF SAFEGUARDING .................................................................................................56-57 SECTION 9—RETURN MATERIALS AUTHORIZATION REQUEST FORM ........................................................... 58 SECTION 10—oRDER FORM FOR SIGNS AND LITERATURE ............................................................................ 59 Copyright © 2017 by Rockford Systems, LLC. All rights reserved. Not to be reproduced in whole or in part without written permission. Litho in U.S.A. Rockford Systems, LLC. 2 Call: 1-800-922-7533 Section 1—in general RHPS Hydraulic Solid-State Control Safety Precautions DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This safety alert symbol identifies important safety messages in this manual. When you see this symbol, be alert to the possibility of personal injury, and carefully read the message that follows. CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. Efficient and safe machine operation depends on the development, implementation and enforcement of a safety program. This program requires, among other things, the proper selection of point-of-operation guards and safety devices for each particular job or operation and a thorough safety training program for all machine personnel. This program should include instruction on the proper operation of the machine, instruction on the point-of-operation guards and safety devices on the machine, and a regularly scheduled inspection and maintenance program. Rules and procedures covering each aspect of your safety program should be developed and published both in an operator’s safety manual, as well as in prominent places throughout the plant and on each machine. Some rules or instructions which must be conveyed to your personnel and incorporated in to your program include: DANGER Never place your hands or any part of your body in this machine. Never operate this machine without proper eye, face and body protection. Never operate this machine unless you are fully trained and instructed and unless you have read the instruction manual. Never operate this machine if it is not working properly—stop operating it and advise your supervisor immediately. Never use a foot switch to operate this machine unless a point-of-operation guard or device is provided and properly maintained. Never operate this machine unless two-hand trip, two-hand control or presence- sensing device is installed at the proper safety distance. Consult your supervisor if you have any questions regarding the proper safety distance. Never tamper with, rewire or bypass any control or component on this machine. A company’s safety program must involve everyone in the company, from top management to operators, since only as a group can any operational problems be identified and resolved. It is everyone’s responsibility to implement and communicate the information and material contained in catalogs and instruction manuals to all persons involved in machine operation. If a language barrier or insufficient education would prevent a person from reading and understanding various literature available, it should be translated, read or interpreted to the person, with assurance that it is understood. FOR MAINTENANCE AND INSPECTION ALWAYS REFER TO THE OEM’S (ORIGINAL EQUIPMENT MANUFACTURER’S) MAINTENANCE MANUAL OR OWNER’S MANUAL. If you do not have an owner’s manual, please contact the original equipment manufacturer. Rockford Systems, LLC. Call: 1-800-922-7533 3 section 1—in general RHPS Hydraulic Solid-State Control Safety References ANSI SAFETY STANDARDS FOR MACHINES The most complete safety standards for machine tools OSH ACT AND FEDERAL REGULATIONS are published in the ANSI (American National Standards Since the enclosed equipment can never overcome Institute) B11 series. The following is a list of each ANSI a mechanical deficiency, defect or malfunction in the B11 Standard available at the printing of this publication. machine itself, OSHA (Occupational Safety and Health B11.1 Mechanical Power Presses Administration) has established certain safety regula- B11.2 Hydraulic